Failure Analysis of High Temperature Nickel Alloy Catalyst Reformer Tubes

Catalytic reformer tubes are subjected to high service temperatures in excess of 900^oC for long periods of time. In order to achieve reasonable service life duration (100,000 hours is a typical service life goal), tubes are composed of high temperature resistant materials, such as creep-resistant, high Ni- and Cr-content cast steel with an austenitic structure. Exceeding normal design operating temperatures in the form of brief or sustained temperature excursions can result in greatly shortened tube life. This case study examines the premature failure of reformer tubes due to long term overheating, which led to thermal degradation and eventual creep rupture of the tube walls.